Testing system for connectors

ABSTRACT

A testing system for connectors usable with oil or natural gas wells using a test part connector and a control component connector. The system uses a test fluid in a test reservoir that is pumped to each connector simultaneously and using a test part pressure transducer and a control component pressure transducer to create a test response and a control response. The responses are then transmitted to a processor, which then compares the responses and presents compared results on a display, through a network and transmitted to a client device of a user.

FIELD

The present application is a continuation in part of U.S. patentapplication Ser. No. 11/766,541 filed on Jun. 21, 2007, entitled “HighPressure Energizable Tube Connector for a Well and Method of Energizingthe Connector” and is also a continuation in part of U.S. patentapplication Ser. No. 12/248,558 filed on Oct. 9, 2008, entitled“Externally Testable Redundant Seal Connector”. These applications areincorporated in their entirety.

FIELD

The present embodiments generally relate to a testing system forconnectors, such as seal connectors and high pressure energizable tubeconnectors, for a well.

BACKGROUND

A need exists for quick testing system for connectors, which providesresults in less than about 5 minutes concerning very small leaks, suchas leaks less than 1×10⁽⁻⁶⁾ cm³, that is highly reliable easy to use,and requires little or no training to conduct.

A further need exists for a testing system that is robust, and canwithstand field tests in sandy locations or hot locations with highaccuracy.

The present embodiments meet these needs.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description will be better understood in conjunction withthe accompanying drawings as follows:

FIG. 1 depicts a top view of an embodiment of a connector for testing.

FIG. 2 depicts a cut view of an embodiment of the connector of FIG. 1along 1A.

FIG. 3 depicts a networkable testing system.

FIG. 4 depicts computer instructions which can be used in the system.

The present embodiments are detailed below with reference to the listedFigures.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Before explaining the present system in detail, it is to be understoodthat the system is not limited to the particular embodiments and that itcan be practiced or carried out in various ways.

The present embodiments relate to testing systems for connectors. Theconnectors can be testable seal connectors, which can be external andredundant, and high pressure energizable tube connectors, such as onefor a well.

The well can be an oil well, a water well, a steam injection well, aninjection well or a similar well. It can be used in a subsea well or aland based well.

The present embodiments can further relate to a connector for a wellthat has a connector body with a thru-bore for flowing fluid down a wellfrom the surface.

The connector body can be threadable with a mandrel to support a checkvalve, a down hole pressure gauge, a down hole temperature gauge, a gaslift valve, or other down hole tools.

The connector body can be made of steel alloy, nickel alloy, carbonsteel, other steel or combinations thereof. It can also be contemplatedthat the connector body can be coated to reduce friction on the threads.

The connector can include a ferrule disposed on an end of the connectorbody. The ferrule can be adapted to slidably engage the outer diameterof the connector body to form a primary seal between the mandrel and anannulus of the well.

The primary seal can be formed by deforming the ferrule usingcompression with the mandrel. Usable ferrules can be purchased fromPetroTechnologies, Inc., of Broussard, La., such as part no. 120M005A.

A first sealing groove can be formed on the outer diameter of theconnector body. More than one sealing groove can be used withaccompanying sealing means if desired. The groove can be about 0.07inches in depth and can be formed of a design that can support an o-ringsealing device, with rounded corners.

At least one first sealing means can be disposed in at least one sealinggroove. It is possible that a second or back up o-ring can be used inthe sealing groove to increase the compression on the o-ring so that nogas flows out of the connector.

At least one test conduit can be formed in the connector body, which canfurther be in parallel to, but disconnected from, the thru-bore and canbe parallel to the body axis. It is contemplated that the test conduitdoes not have to be parallel to the body axis. The test conduit can beplaced at an angle to the body axis in the connector body. The testconduit can comprise a test conduit diameter ranging from about 0.015inches to about 0.125 inches.

A test port can be disposed in the connector body for receiving a testfluid, and introducing the test fluid to at least one test conduit. Thetest port can have a test port diameter ranging from about 0.015625inches to about 0.5 inches. The test port can be cylindrical with atapered metal to metal seal at one end. It can also be contemplated thatthe test port can have a threaded engagement for receiving a test plug.The test port can include a removable and re-installable test port plug.The test port can include an access hole having a diameter ranging fromabout 1/32 inches to about 1/16 inches.

The testing system externally tests a connector for a fluid conduit todetermine leak rates which are less than 1×10⁽⁻⁶⁾ cm³ within 5 minutes.

The testing system can use at least one test part connector and acontrol component connector for testing in tandem simultaneously.

The test system can use a test fluid from a test reservoir and a pumpfor pumping the test fluid from the test reservoir to the test partconnector and the control component connector simultaneously at similarpressures.

The similar pressures do not have to be identical pressures, but can beidentical pressures in an embodiment. A computer program can permit auser to test at two different pressures in the test part and the controlcomponent, and then adjust the pressures to provide a “normal” pressurefor correct and highly accurate comparison purposes between the testpart and the control component. The variation in pressures and testresponse over time can be translated to a volume using a simplemathematical conversion known to those ordinarily skilled in the art todetect leaks as small as 10⁻⁶ cm³ over a five minute period.

A test part pressure transducer and a control component pressuretransducer can be used in the testing system. The test part pressuretransducer can detect and transmit a test response when a first portionof test fluid is pumped to the test part simultaneously with the controlcomponent pressure transducer for detecting and transmitting a controlresponse when a second portion of test fluid is pumped to the controlcomponent connector.

In an embodiment of the testing system, the first portion of test fluidis independently pumped and pressured from the second portion of testfluid.

The testing system uses a data storage that is in communication with thetest part pressure transducer and control component pressure transducer.The data storage records the test response and control response.

The testing system can use a means for communicating with the datastorage, such as a cell phone, a laptop, a computer monitor, which usescomputer instructions in the data storage for comparing the testresponse and the control response. The means for communicating can thenform “compared results” and present the “compared results” to a userwithin 5 minutes of pumping the test fluid to the test part connectorand the control component connector. The means for communicating andpresenting the compared results does not use (or need to use) amathematical model of o-ring extrusion which is a complicated formulathat can take time to run and computer. The means for communicating doesnot use (or need to use) a mathematical model representing a contractionof the test fluid in the test part due to the cooling of the test fluidduring pumping.

It can be contemplated that one or more test ports can receive the testfluid.

The test fluid can be water, compressed air, oil, compressed nitrogen,compressed helium, another compressed inert gas or combinations thereof.

In an embodiment, the test fluid can be at a pressure from about 1 atmto about 40,000 psi.

The test pump can be a small hand pump, an ENERPAC pump or any pumpcapable of flowing from about 1 milliliter to about 10 milliliters ofgas or fluid into the test conduit and can also be adapted to reach atest pressure from about 1000 psi to about 20000 psi.

It can be contemplated that the test plug can be removed for testing andre-installed into the test port upon completion of testing. Each testplug can form a secondary seal between the annulus of the well and thethru-bore of the connector.

In an embodiment of the testing system, the data storage can containcomputer instructions for enabling a processor or the means forcommunicating to provide a “pass” response to the user when the testpart response is within 10 percent of the control component response.The “pass” response would mean the part passes the test, and that it iswithin the desired tolerances. Although the tolerances can be within 10percent, a user can adjust the tolerances to smaller numbers and as lowas 0.1 percent.

The data storage can also contain computer instructions for enabling themeans for communicating, which can be a processor, to provide a greenscreen as a response for the user when the test part response is withinup to 10 percent of the control component response. The term “greenscreen” refers to using a version of the actual color green on theentire screen for a user to quickly see that the test part “passes” thetest. Similarly, a red screen meaning the test part fails the test canbe used.

The testing system can include computer instructions in the data storagefor enabling the means for communicating to provide a screen color otherthan green as a response for the user when the test part responsedeviates more than 10 percent from the control component response. Thecolor can be pink, blue, striped, have shapes and/or icons, can useblinking or other visible warning indicators on pass or fail for thetest.

The testing system can include the step of presenting the comparedresults to a user on a client device. The compared results can betransmitted by the means for communicating to a network which can be incommunication with the client device.

The client device can be a cell phone, a laptop, a desk computer, apersonal digital assistant, a global positioning system “GPS” withmonitoring display and processor, or similar device with a processorthat can be connectable to the network. The network can be a cellularnetwork a satellite network, a local area network, a global positioningsystem network or even the Internet™.

In an embodiment, the testing system can use an electric pump, and theelectric pump can then be connected to a power supply such as batteries,or a 110 volt supply from a generator.

Referring now to the Figures, FIG. 1 shows a connector having aconnector body 10, a connector body axis 11 and a thru-bore 12. Thethru-bore can have a diameter ranging from about 0.1 inches to about 1.5inches.

The thru-bore can pass methanol, a hydrate inhibitor or paraffininhibitor, a hydraulic fluid to operate a valve, or a fluid to operate asliding sleeve. The fluid passing though the thru-bore can flow at up toabout 10 gallons per minute. The thru-bore fluid pressure can be used tomonitor pressure inside the production tubing, inside the mandrel, orinside the well.

In an embodiment, fluid can be pumped into the connector or theconnector can be screwed to a gauge to read the surrounding pressure offluid in the well.

The connector body 10 can have a first connector end 13 and a secondconnector end 14 opposite the first end. The connector body can have adiameter ranging from about 0.5 inches to about 2 inches and can have alength of from about 0.5 inches to about 5 inches.

FIG. 2 shows a cut view of a ferrule 16 disposed on the first connectorend 13 of the connector body 10. The ferrule can be made a high nickelalloy ferrule to prevent corrosion. The ferrule can form a primary seal15 between the outer diameter of the connector body 10 and a profile 20in a mandrel 22. The primary seal can prevent fluid of the thru-borefrom reaching the fluid of the annulus.

A first sealing groove 24 can be formed on the outer diameter of theconnector body 10 and at least one first sealing means 26 can bedisposed in the first sealing groove 24. The first sealing means can bean o-ring, an energizable rotatable flexible metal seal, a metal tometal seal or combinations thereof.

A test conduit 28 can be formed in the connector body 10 and can beadjacent to the thru-bore 12. The test conduit can be straight, curvedor other patterns as well.

While FIG. 2 depicts one test conduit 28, it can contemplated that morethan one test conduit can be formed in the connector body 10.

In this Figure, two test ports 32 a, 32 b are also shown and can bedisposed in the connector body 10 for receiving a test fluid 34, whichcan be seen in FIG. 3. It can be contemplated that only one test port isused. It can further be contemplated that more then one test port can beused.

In an embodiment, a test plug can be used with the system and can beremoved for testing and re-installed into the test port upon completionof testing.

FIG. 3 depicts the networkable testing system in connection with theconnector.

Each test port 32 a, 32 b can receive test fluid 34 from a testreservoir 30, or a secondary source. It is contemplated that the testfluid 34 can be water, compressed air, oil, compressed nitrogen,compressed helium, another compressed inert gas or combinations thereof.

A pump 50 can pump the test fluid from the test reservoir 30 to the testpart connector 48 and the control component connector 49 simultaneouslyat similar pressure though the test conduit 28 and the control conduit29.

The pump can further be powered by a power supply 51. The power supplycan be batteries, a 110 volt supply from a generator, or an additionalpower supply

The test fluid can be introduced to at least one of the test conduitsfor testing using the pump, wherein the pump pressures are up to about20,000 psi.

The test fluid 34 is passed through the test part pressure transducer 52and the control component pressure transducer 54. The test part pressuretransducer 52 detects and transmits a test response 56 when a firstportion of the test fluid is pumped to the test part connector 48simultaneously with the control component pressure transducer 54detecting and transmitting a control response 58 when a second portionof the test fluid is pumped to the control component connector 49. Thefirst portion of the test fluid is independently pumped and pressuredfrom the second portion of the test fluid.

FIG. 3 also shows data storage in communication with the test partpressure transducer 52 and control component pressure transducer 54 withcomputer instructions for recording the test response 56 and controlresponse 58.

The compared results 65 are then presented on a compared results display67 to a user on a client device 70. The compared results 65 can betransmitted by the means for communicating 74 to a network 72, which canbe in communication with the client device 70.

Once testing is complete, a test plug can be inserted into each of thetest ports on the connector body. Each test plug can form a secondaryseal.

FIG. 4 shows computer instructions for recording the test response andthe control response 61, which is depicted in the data storage 60, whichis also shown in communication with the means for communicating 74.

The system can also include computer instructions for comparing the testresponse and the control response forming compared results andpresenting the compared results to a user within 5 minutes of pumpingthe test fluid to the test part connector and the control componentconnector 62.

The system can include computer instructions in the data storage forenabling the means for communicating to provide a “pass” response to theuser when the test part response is within 10 percent of the controlcomponent response 64.

The system can include computer instructions in the data storage forenabling the means for communicating to provide a green screen as aresponse to the user when the test part response is within 10 percent ofthe control component response 66.

The system can also include computer instructions in the data storagefor enabling the means for communicating to provide a screen color otherthan green as a response to the user when the test part responsedeviates more than 10 percent from the control component response 68.

While these embodiments have been described with emphasis on theembodiments, it should be understood that within the scope of theappended claims, the embodiments might be practiced other than asspecifically described herein.

What is claimed is:
 1. A system for externally testing connector for afluid conduit to determine leak rates which are less than 1×10⁽⁻⁶⁾ cm³within 5 minutes comprising: a. at least one test part connector,wherein the test part connector is disposed in a well, and a controlcomponent connector, wherein the control component connector is at asurface, and wherein the test part connector and the control componentconnector are tested in tandem simultaneously, wherein each connectorcomprises: i. a connector body having a thru-bore comprising a firstconnector end and a second connector end and a connector body axis; ii.a ferrule disposed on the first connector end of the connector body,wherein the ferrule is adapted for forming a primary seal between anouter diameter of the connector body and a profile in a mandrel; iii. atleast a first sealing groove formed on the outer diameter of theconnector body; iv. at least one first sealing means disposed in the atleast one first sealing groove; v. at least one test conduit formed inthe connector body adjacent to the ferrule and disconnected from thethru-bore; vi. at least one test port disposed in the connector body forreceiving test fluid and introducing test fluid to one of the at leastone test conduit; and vii. a test plug insertable in each test port uponcompletion of testing, wherein each test plug forms a secondary sealbetween the connector body and the mandrel; b. a test fluid in a testreservoir; c. a pump for pumping the test fluid from the test reservoirto the test part connector and the control component connectorsimultaneously, wherein the pump is in fluid communication with the testpart connector by a first conduit, and the pump is in fluidcommunication with the control component connector via a second conduit,configuring the system to simultaneously test at two different pressuresand compare pressures in the test part connector and the controlcomponent connector to determine leaks as small as 10⁻⁶ cm³ over a fiveminute period; d. a test part pressure transducer and a controlcomponent pressure transducer, wherein the test part pressure transducerdetects and transmits a test response when a first portion of the testfluid is pumped to the test part connector simultaneously with thecontrol component pressure transducer detecting and transmitting acontrol response when a second portion of the test fluid is pumped tothe control component connector, and wherein the first portion of thetest fluid is independently pumped and pressured from the second portionof the test fluid; e. a data storage in communication with the test partpressure transducer and control component pressure transducer withcomputer instructions for recording the test response and controlresponse; and f. means for communicating with the data storage usingcomputer instructions in the data storage for comparing the testresponse and the control response forming compared results andpresenting the compared results to the user within 5 minutes of pumpingthe test fluid to the test part connector and the control componentconnector without using a mathematical model of o-ring extrusion andwithout using a mathematical model representing a contraction of thetest fluid in the test part due to the cooling of the test fluid duringpumping.
 2. The system of claim 1, further comprising computerinstructions in the data storage for enabling the means forcommunicating to provide a “pass” response to the user when the testpart response is within 10 percent of the control component response. 3.The system of claim 2, further comprising computer instructions in thedata storage for enabling the means for communicating to provide a greenscreen as a response to the user when the test part response is within10 percent of the control component response.
 4. The system of claim 2,further comprising computer instructions in the data storage forenabling the means for communicating to provide a screen color otherthan green as a response to the user when the test part responsedeviates more than 10 percent from the control component response. 5.The system of claim 1, wherein the compared results are presented to theuser on a client device.
 6. The system of claim 5, wherein the clientdevice is a cell phone, a laptop, a desk computer, a personal digitalassistant, a global positioning system “GPS” with monitoring display andprocessor, or similar device with processor that is connectable to anetwork.
 7. The system of claim 1, wherein the connector body comprisesan outer diameter ranging from 0.50 inches to 2 inches.
 8. The system ofclaim 1, wherein the connector body comprises steel alloy, nickel alloy,carbon steel, other steel, or combinations thereof.
 9. The system ofclaim 1, wherein the thru-bore has a diameter ranging from 0.1 inches to1.5 inches.
 10. The system of claim 1, wherein the connector body isthreadable with the mandrel to support a check valve, a down holepressure gauge, a down hole temperature gauge, a gas lift valve, orother down hole tools.
 11. The system of claim 1, wherein the connectorbody is from 0.5 inches to 5 inches in length.
 12. The system of claim1, wherein the ferrule slidingly engages the outer diameter of theconnector body and forms the primary seal between the mandrel and anannulus of the well.
 13. The system of claim 1, wherein the test portflows the test fluid from a secondary source to the test conduit. 14.The system of claim 13, wherein the test fluid is selected from thegroup consisting of: water, compressed air, oil, compressed nitrogen,compressed helium, and another compressed inert gas.
 15. The system ofclaim 14, wherein the test fluid is at a pressure from 1 atm to 40,000psi.
 16. The system of claim 1, wherein the test conduit comprises atest conduit diameter ranging from 0.015 inches to 0.125 inches.
 17. Thesystem of claim 1, wherein the at least one first sealing means is atleast one o-ring.
 18. The system of claim 1, wherein the at least onefirst sealing means is at least one energizable rotatable flexible metalseal.
 19. The system of claim 1, wherein the at least one first sealingmeans is a metal to metal seal.
 20. The system of claim 1, wherein thetest plug is removable and re-installable.
 21. The system of claim 1,wherein the pump is connected to a power supply.
 22. The system of claim1, wherein the similar pressures of the test fluid to the test partconnector and the pressure to the control component connector areidentical.